Packaging bags, packaging systems, methods of shipping, and methods of manufacturing packaging systems

ABSTRACT

Packaging systems and methods are provided in which a shipping bag has an inner surface and an outer surface and a plurality of cushion pieces are directly affixed to the inner surface, the outer surface, or both the inner and outer surface of the shipping bag by an adhesive. The cushion pieces may be dispersed at various locations inside or outside the shipping bag to protect a unit being packaged and arranged to achieve optimal load bearing for a unit being packaged. In exemplary embodiments, each cushion piece is located at an optimal location one or more of the inner and outer surface of the shipping bag relative to a unit being packaged. Each cushion piece can automatically locate itself at an optimal location on one or more of the inner and outer surface of the shipping bag relative to a unit being packaged. Exemplary methods further comprise determining an optimal location for each cushion piece relative to the unit based on the optimized load bearing and transferring each optimal location to the inner surface of the shipping bag. The step of determining an optimized load bearing for the unit to be shipped may comprise weighing the unit and referring to cushioning curve data for the material of the shipping bag.

FIELD

The present disclosure relates to packaging bags and packaging systems, methods of packaging and shipping, and methods of manufacturing packaging systems.

BACKGROUND

Cushioning devices for product packaging and shipping are increasingly needed as global trade continues to expand. As more complicated and expensive electronics devices and industrial products are shipped around the world, there is a need for more sophisticated and more effective shock absorbing cushioning devices to protect these products during shipping. But existing packaging systems that seek to provide more sophisticated solutions typically come at the cost of requiring a multi-step packing process for transitional packaging.

Some known packaging materials and devices include bubble wrap, air bags, honeycomb cardboard, and polystyrene (styrofoam peanuts). Some of these materials are heavy and therefore increase shipping and fuel costs. Other known packaging materials, such as polystyrene blocks or molded plastics, are designed and manufactured specifically for particular products. However, this can be wasteful and unduly expensive as different specialty materials need to be made for a large variety of different products and cannot typically be re-used. Other materials such as air bags and bubble wrap often get destroyed in shipping and cannot be re-used. Furthermore, many of the plastics and polystyrene materials are not recyclable or biodegradable.

Many sophisticated electronics devices are fragile and need to be protected from impact during shipping. Product fragility is measured in both cosmetic and structure values. The latter is measured in G levels of the amount of shock a specific product can withstand prior to incurring damage. Existing solutions to address product fragility during shipping include various end caps and top and bottom caps made of foam to protect the products being shipped. However, these solutions are inefficient and waste materials as they require the use of a complete end cap, or a complete top and bottom tray of foam regardless of the amount of foam actually required to protect the product during transit. This results in increased material costs, increased labor costs, and a significant increase in environmental waste.

Accordingly, there is a need for a packaging system that can be universally used to ship a large variety of different products. There also is a need for a packaging system that is relatively cheap, easily manufactured and scalable. There is a need for a packaging system that effectively and efficiently addresses product fragility. There is also a need for a packaging system that provides a one-step solution for users. Finally, there is a need for a packaging system that provides for exact product fragility protection during transit and is a recyclable solution.

SUMMARY

The embodiments of the present disclosure alleviate to a great extent the disadvantages of known packaging systems and methods by providing a packaging system including a shipping bag and a plurality of cushion pieces directly affixed to one or more of the inner and outer surface of the shipping bag by an adhesive. Disclosed packaging systems and methods utilize engineered foam laminated to specific locations on a polyethylene bag and/or gusset bag to strategically and cost effectively protect products in transit. Disclosed packaging systems and methods utilize a new design methodology and material optimization combinations that provide for exact product fragility protection during transit as well as providing for a 100% recyclable solution.

Disclosed embodiments provide for the exact amount of cushioning material required in the exact location needed to protect the product during transit. This ability to position the exact amount of foam in the exact locations needed optimizes material usage, reduces labor costs, and decreases environmental waste. Disclosed embodiments of packaging systems and methods provide ease of packaging use for products of any shape and weight and provide direct specific directional cushioning protection to the products only where it is needed, thereby reducing costs over traditional cushioning solutions. Disclosed embodiments also reduce material waste over traditional packaging designs and reduce packaging weight.

Exemplary embodiments of a packaging system comprise a shipping bag having an inner surface and an outer surface and a plurality of cushion pieces directly affixed to the inner surface of the shipping bag by an adhesive. The cushion pieces may be dispersed at various locations within the shipping bag to protect a unit being packaged. In exemplary embodiments, the cushion pieces are arranged to achieve optimal load bearing for a unit being packaged. In exemplary embodiments, each cushion piece is located at an optimal location on the inner surface of the shipping bag relative to a unit being packaged. Each cushion piece can automatically locate itself at an optimal location on the inner surface of the shipping bag relative to a unit being packaged. In exemplary embodiments, the shipping bag is made of a waterproof material such that it provides a moisture barrier. The system may further comprise a shipping carton configured to house the shipping bag.

Exemplary embodiments include methods of packaging a unit for shipping. Exemplary packaging methods comprise providing a shipping bag, providing a plurality of cushion pieces, and determining an optimized load bearing for a unit to be shipped. The shipping bag may be made of a material suitable for shipping and has an inner surface and an outer surface. Exemplary methods further comprise determining an optimal location for each cushion piece relative to the unit based on the optimized load bearing and transferring each optimal location to the inner surface of the shipping bag. Exemplary methods further comprise directly affixing each cushion piece to one or more of the inner and outer surface of the shipping bag at its optimal location using adhesive. In exemplary embodiments, each cushion piece automatically locates itself at each respective optimal location on one or more of the inner and outer surface of the shipping bag relative to the unit.

In exemplary embodiments, the step of determining an optimized load bearing for the unit to be shipped comprises weighing the unit and referring to cushioning curve data for the material of the shipping bag. The methods may further comprise placing the unit inside the shipping bag. The methods may further comprise sealing the shipping bag. The methods may further comprise placing the shipping bag inside a shipping carton. In exemplary embodiments, disclosed methods further comprise removing the shipping bag from the shipping carton, unsealing the shipping bag, removing the unit from the shipping bag, and re-using the shipping bag to ship another unit.

Exemplary embodiments of a packaging system comprise a shipping bag having an inner surface and an outer surface and a plurality of cushion pieces directly affixed to one or more of the inner and outer surface of the shipping bag by an adhesive. In exemplary embodiments, the cushion pieces are dispersed at various locations within the shipping bag to protect a unit being packaged. The cushion pieces may be arranged to achieve optimal load bearing for the unit being packaged. In exemplary embodiments, the optimized load bearing for the unit to be packaged is determined by a weight of the unit and cushioning curve data for the shipping bag. In exemplary embodiments, each cushion piece is located at an optimal location on one or more of the inner and outer surface of the shipping bag relative to a unit being packaged. In exemplary embodiments, each cushion piece automatically locates itself at an optimal location on one or more of the inner and outer surface of the shipping bag relative to a unit being packaged. In exemplary embodiments, the shipping bag is made of polyethylene. In exemplary embodiments, the cushion pieces are made of polyethylene.

Accordingly, it is seen that packaging systems and methods are provided which strategically and cost effectively protect products in transit. The disclosed systems and methods include a shipping bag and a plurality of cushion pieces directly affixed to the inner surface of the shipping bag by an adhesive. Each cushion piece is located at an optimal location on one or more of the inner and outer surface of the shipping bag relative to a unit being packaged. The packaging systems and methods are relatively cheap, easily manufacturable and scalable and direct specific directional cushioning protection to the products where is it needed. These and other features and advantages will be appreciated from review of the following detailed description, along with the accompanying figures in which like reference numbers refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects of the disclosure will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which:

FIG. 1A is a top perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 1B is a front view of the packaging system of FIG. 1A;

FIG. 1C is side perspective view of the packaging system of FIG. 1A;

FIG. 2A is a front perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 2B is a rear perspective view of the packaging system of FIG. 2A;

FIG. 2C is a side view of the packaging system of FIG. 2A;

FIG. 3A is a perspective view of an exemplary embodiment of a shipping bag in accordance with the present disclosure;

FIG. 3B is a side view of the shipping bag of FIG. 3A;

FIG. 4A is a perspective view of an exemplary embodiment of a shipping bag in accordance with the present disclosure;

FIG. 4B is a top front view of the shipping bag of FIG. 4A;

FIG. 4C is a bottom front view of the shipping bag of FIG. 4A;

FIG. 4D is a top view of the shipping bag of FIG. 4A;

FIG. 5 is a perspective view of an exemplary embodiment of a shipping bag in accordance with the present disclosure;

FIG. 6A is a front view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 6B is a side view of the packaging system of FIG. 6A;

FIG. 6C is a rear view of the packaging system of FIG. 6A;

FIG. 7A is a top perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 7B is a side perspective view of the packaging system of FIG. 7A;

FIG. 8A is a top perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 8B is a top perspective view of the packaging system of FIG. 8A;

FIG. 9A is a perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 9B is a top view of the packaging system of FIG. 9A;

FIG. 9C is a side view of the packaging system of FIG. 9A;

FIG. 10A is a perspective view of an exemplary embodiment of a honeycomb configuration of cushion pieces in accordance with the present disclosure;

FIG. 10B is a top view of the honeycomb configuration of FIG. 10A;

FIG. 11 is a top view of an exemplary embodiment of a honeycomb configuration of cushion pieces in accordance with the present disclosure;

FIG. 12 is a top view of an exemplary embodiment of a honeycomb configuration of cushion pieces in accordance with the present disclosure;

FIG. 13A is a front perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 13B is a rear perspective view of the packaging system of FIG. 13A;

FIG. 13C is a side perspective view of the packaging system of FIG. 13A;

FIG. 14A is a front perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 14B is a side perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 15A is a top perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure;

FIG. 15B is a detail view of the packaging system of FIG. 15A; and

FIG. 16 is a perspective view of an exemplary embodiment of a packaging system in accordance with the present disclosure.

DETAILED DESCRIPTION

In the following paragraphs, embodiments will be described in detail by way of example with reference to the accompanying drawings, which are not drawn to scale, and the illustrated components are not necessarily drawn proportionately to one another. Throughout this description, the embodiments and examples shown should be considered as exemplars, rather than as limitations of the present disclosure. As used herein, the “present disclosure” refers to any one of the embodiments described herein, and any equivalents. Furthermore, reference to various aspects of the disclosure throughout this document does not mean that all claimed embodiments or methods must include the referenced aspects.

Referring to FIGS. 1A-1C and 2A-2C, an exemplary embodiment of a packaging system will be described. Packaging system 10 comprises a shipping bag 12 and a plurality of cushion pieces 14. As described in more detail herein, the cushion pieces 14 are affixed to a surface of the shipping bag 12 to advantageously provide exact product fragility protection during transit. The bag 12 may be any kind of bag suitable for shipping made of any suitably strong material. In exemplary embodiments, the shipping bag is made of a waterproof material to provide a moisture barrier for the unit 22 being shipped. In exemplary embodiments, as shown in FIGS. 3A and 3B, the shipping bag 12 is made of polyethylene. More particularly, the bag 12 may be made of polyethylene shrink film, which is used for industrial packaging because of its thickness and strength. One advantage of polyethylene shrink film is that one size can fit many different types of products.

However, polyethylene bags typically are not available in a wide variety of shapes and sizes and have a relatively high production cost. Also, they are provided in one-layer rolls. In exemplary embodiments, as shown in FIGS. 4A-4D, the shipping bag 12 is a gusset bag, which has a relatively low production cost compared to a polyethylene bag and can be ordered in large quantities, typically in cases of 500-1000 bags. Furthermore, gusset bags are available in custom sizes and come in bottom gusset and side gusset varieties. Accordingly, the person of ordinary skill in the art could, based on various considerations, elect to use polyethylene bags or gusset bags depending on the circumstances. For example, a gusset bag might be used as the shipping bag 12 in situations where a custom sized bag is needed, such as where the product is of an unusual shape.

A bottom or side gusset bag might be selected depending on the shape and size of the product or unit to be shipped. A bottom gusset bag is suitable for use with products which have flat, small bottoms, such as 3-5 inches wide. A side gusset bag may be more suitable for medium-sized and larger products or units. While the standard thickness of a gusset bag is 2 or 3 ml (holding 5-15 pounds), heavier products such as industrial parts and heavy machinery might require thicker bags such as 4 ml or above. In addition, products with sharp edges, fragile edges or fragile components might need higher thicknesses.

The size and dimensions of the shipping bag may vary depending on the size of the product or unit to be shipped. Exemplary polyethylene shipping bags useful in packaging applications may be 15 inches in width by 13 inches in depth by 22 inches in length. Exemplary gusset bags also useful for packaging may be 14 inches in width by 8 inches in depth by 18 inches in length. Other exemplary gusset bag packaging solutions could be a one 2 ml and one 3 ml side gusset bag having the dimensions 14×14×26 (e.g., made by Custom Poly Packaging) or one 3 ml and one 1.5 ml side gusset bag having the dimensions 12×8×30 (e.g., made by Huckster Packaging and Supply). The skilled artisan would be able to determine a suitably sized bag for a particular product or unit to be shipped. By way of example only, an HP Printer with the dimensions 13.75-inch width×7.5-inch depth×8.5-inch length would fit in a shipping bag with the dimensions 18-inch width×8-inch depth×13-inch length.

As best seen in FIGS. 4B and 4C, an exemplary shipping bag 12 has an inner surface 16 and an outer surface 18. The cushion pieces 14 are affixed to either the inner surface 16 or the outer surface 18 of the bag 12. In exemplary embodiments, the cushion pieces 14 are adhered directly to the inner surface 16 of the shipping bag 12 to achieve a total packaging solution. This adhesion may be accomplished by use of a special adhesive 20, as shown in FIG. 5. Polyethylene is a chemical-resistant material with a low coefficient of friction, i.e. a “high slip” material, so most materials and objects do not stick to it. Thus, a very strong adhesive which will bond well with the cushion pieces 14 is necessary. Advantageously, special adhesive types used are double-sided tape such as Killer Polyester Clear Red Tape (E Plastic: ridout plastic) and VHB Tape by 3M, glue, or spray adhesives such as 90 spray adhesive by 3M. In exemplary embodiments, a wide double-sided tape is used. In exemplary embodiments, the adhesive is strong enough that the seal between the surface of the bag and the cushion pieces breaks when the bag surface and cushion pieces are pulled apart.

A plurality of cushion pieces 14, 114 are provided. The cushion pieces 14, 114 may be of various dimensions, shapes, and materials depending on the application. In exemplary embodiments, the cushion pieces are made of polyethylene foam, but other materials may be used, including but not limited to polyurethane foam, polypropylene foam, and closed-cell cross-link foam. Each of these materials were found to perform well in capturing the unit to be shipped and sufficiently protecting various products. The cushion pieces 14 may be of any shape suitable for cushioning products to be shipped, including but not limited to rectangular, square, ovular, hexagonal, etc. The dimensions of the cushion pieces 14 may vary depending on the size of the shipping bag 12 used and the size and shape of the product to be shipped. In exemplary embodiments, the cushion pieces 14 are in the form of blocks. Exemplary cushion block dimensions are four inches in length by one inch in width by 1-1.5 inches in height. Larger or smaller cushion pieces with differing dimensions may be used, and multiple sizes may be used in the same shipping bag to ship a single product.

Turning to FIGS. 7A-7B, 8A-8B and 9A-9C, in exemplary embodiments, the cushion pieces 114 are in the form of discs. In exemplary embodiments, the disc-like cushion pieces 114 are hexagonal in shape. Other shapes could also be used, as needed, depending on the product to be packaged, including but not limited to circles, squares, triangles, rectangles, cones, and other geometric shapes. The inherent design concept of providing the exact amount of cushioning needed to the exact location on the product, as described in more detail herein, remains intact with various shapes. The hex-shaped pattern allows for various hex-shaped sizes and varying densities of materials to be used depending on the weight and dimensions of the product to be packaged and scales with any sized product to be shipped. The skilled artisan will recognize that hex sizes, thicknesses, patterns, and materials may vary depending on the product being packaged.

The hex-shaped cushion pieces 114 are advantageously provided in the exact size and thickness needed to protect any given product during transportation. The individual hex-shaped cushion pieces 114 act independently of each other and react only to forces applied to each respective hex-shaped cushion piece 114. This allows the reduction of G levels imparted to the unit during transit and testing.

As illustrated in FIGS. 10A-10B, 11 and 12, the hex-shaped cushion pieces 114 can be arranged to form a honeycomb configuration 115 of cushioning material, which can be adhered to the shipping bag 12. The cushion pieces 14, 114 can be adhered to the bag 12 by adhesive 20, either applied to the inner or outer surface of the bag or in the form of an adhesive backing, as shown in FIG. 10A. The hex-shaped cushion pieces 114 can be fabricated and formed into honeycomb configurations 115 by having the side surfaces of the inner pieces 114, or inside lines, kiss cut (represented by dashed lines in FIG. 10B) and the outside surfaces or outside lines cut all the way through (represented by solid lines in FIG. 10B). Exemplary hexagonal cushion disc 114 dimensions may be ¾ of an inch in hexagon diameter and about ⅝ of an inch in material thickness (FIGS. 10A-10B), ⅝ of an inch in hexagon diameter and ⅜ of an inch in material thickness (FIG. 11), or ⅜ of an inch in hexagon diameter and ¼ of an inch in material thickness (FIG. 12), but a range of other dimensions may be used depending on the application.

As discussed in more detail herein, each hex-shaped pattern created to protect the product in transit will conform to the inside of the shipping bag or carton and “find” its own bearing area within the bag or carton. This allows for variations in the product itself to be compensated for and protected during transit and testing. This occurs because each hex-shaped section of the pattern acts independently, and will compress or expand as the space inside the carton allows. The system of hex-shaped cushion pieces 114 adhered to the shipping bag 12 is a significant departure from traditional end cap and top and bottom tray capture of products used with traditional packaging methods. This solution allows for the removal of traditional end cap or top and bottom tray packaging as the hex pattern foam provides the cushioning of the product during transit.

Referring again to FIGS. 1A-1C and 2A-2C, cushion pieces 14 may be directly adhered to the inner surface 16 of the shipping bag 12 at various locations. Advantageously, the cushion pieces 14 are dispersed at various locations within the shipping bag 12 to protect the unit 22 being packaged. In exemplary embodiments, the cushion pieces 14 are arranged to achieve optimal load bearing for the unit 22. As described in more detail herein, certain factors such as the weight of the unit and cushioning data for the cushion pieces can be used to determine the optimized load bearing for a particular unit.

The optimum design loading for each unit can be determined and the cushion pieces 14 distributed within or outside the shipping bag 12 in accordance with that information. More particularly, as best seen in FIGS. 1A-2C and 6A-6C, each cushion piece 14 can be located at an optimal location 28 on the inner surface 16 of the shipping bag 12 relative to the unit 22 being packaged to provide the correct level of pressure and load absorption on the unit. The packager could apply adhesive and affix the cushion pieces 14 to the bag surface at these locations. As discussed in more detail below, with the adhesive applied at the appropriate locations 28 on the inner or outer surface of the shipping bag 12, each cushion piece 14 automatically locates itself at an optimal location 28 on the surface of the shipping bag 12 relative to the unit 22 being packaged.

With reference to FIGS. 13A-13C, it can be seen that the cushion pieces 14 may be affixed to the inner surface 16 of the shipping bag 12, the outer surface 18 of the shipping bag 12, or both the inner and outer surfaces. In exemplary embodiments, adhesive is applied to the inner surface 16 of the shipping bag 12. The cushion pieces 14 are then adhered to the inner surface 16 of the bag 12 at the optimal locations 28. In addition, or instead, the adhesive may be applied to the outer surface 18 of the shipping bag 12 and the cushion pieces 14 adhered to the outer surface of the bag at optimal locations 28 on the outer surface. After the unit 22 is placed into the shipping bag 12 and the bag tightly sealed, the cushion pieces 14 will move to their optimal positions relative to and in contact with the packaged unit 22. As shown in FIGS. 14A and 14B, end caps 24 could also be disposed on the ends of the bagged unit. A shipping carton 26 configured to house the bagged unit, shown in FIG. 16, may be provided.

In operation, first the unit to be shipped is evaluated. More particularly, the unit 22 is weighed and measured to ascertain its dimensions such as width, depth, and length. The unit also is examined to determine whether it has any sharp edges, fragile edges or fragile components that would require any special bag material thicknesses or other properties of the bag. The user or packager then selects a shipping bag 12 made of suitable material such as polyethylene or selects an appropriately sized gusset bag. More particularly, the dimensions of the shipping bag 12 are selected so the interior of the bag has ample space to receive the unit 22 and the cushion pieces 14, but also so the bag is small enough to snugly and securely fit the unit 22.

The packager then selects an appropriate number of cushion pieces 14, 114 of suitable size for the unit to be shipped. In exemplary embodiments for packaging medium-sized units, the packager could use twelve cushion pieces. However, smaller units may require as few as two cushion pieces, and very large units might need over twenty. The cushion pieces 14 may be of the block form having exemplary dimensions of four inches in length by one inch in width by 1-1.5 inches in height. Larger or smaller cushion pieces may be used, and the user may elect to use cushion pieces of varying sizes to ship the unit. Instead, or in addition, disc-like cushion pieces 114 of a hexagonal shape or other shapes could be used, as shown in FIGS. 7A-12.

With the appropriate shipping bag 12 and cushion pieces 14, 114 selected, the user now conducts an analysis to determine the proper size and optimized locations for the cushion pieces 14, 114 on the surface of the bag 12. Initially, the packager determines the optimized load bearing for the cushion pieces 14, 114 to provide for the unit 22 using the weight of the unit and by referencing cushioning curves for the cushioning material of the cushion pieces 14, 114. Particular electronics products or other equipment may be designed to absorb a maximum amount of force or shock, or manufacturers may recommend that the products be exposed to less than a certain amount of force or shock. By way of example, the optimum design loading for a product used to test exemplary embodiments was 1.35 psi to achieve <100G's of shock when dropped from 30″ height. In the testing of exemplary embodiments, the level of force expected was 60-90G's, up to about 120G's maximum. However, the actual force was lower than expected, staying mostly in the range of 40-60G's with 80G's being the highest level.

By reviewing data for the load bearing of the cushioning material used for the cushion pieces 14, 114, the user can select pieces of the proper size to provide the necessary load bearing for the unit, thereby matching the protection provided by the cushion pieces 14, 114 with the protective needs of the unit 22 being packaged. Furthermore, these load data parameters allow the user to determine the optimal location for each cushion piece 14, 114 relative to the unit 22 based on the optimized load bearing. The location of the cushion pieces on the bag and thus protecting the unit are a function of how much bearing area is needed on any given side of the unit being packaged. The thickness of the cushion pieces will dictate the G levels depending on the bearing area loading. Another requirement is to ensure that the unit is stable in each of the six (6) directions during transit. This applies to the block form cushion pieces as well as the hex- or other disc-shaped cushion pieces.

The user than transfers each such optimal location to the inner surface 16 or outer surface 18 of the shipping bag 12. More particularly, the packager applies adhesive 20 to those locations on the inner or outer surface 16, 18 of the shipping bag 12 or to the cushion pieces 14, 114. Then, in exemplary embodiments, the packager places the cushion pieces 14, 114 within the shipping bag 12 and affixes them so they adhere to the inner surface 16 of the bag 12 at the optimal locations 28. Alternatively, the user may adhere the cushion pieces 14, 114 to the outer surface 18 of the shipping bag 12 at the optimal locations 24.

The user then places the unit 22 to be shipped inside the shipping bag 12 so it fits snugly in the bag and is in contact with the cushion pieces 14, 114. Alternatively, the shipping bag 12 could be placed on or around the unit 22. The packager seals the shipping bag 12 with tape, adhesive, or other fasteners. When the shipping bag 12 is sealed, the cushion pieces 14, 114 automatically locate to their precise required positions relative to the unit 22. More particularly, because the cushion pieces 14, 114 have been affixed to the inner surface 16 or outer surface 18 of the shipping bag 12 at the determined optimal locations 28, the tightening of the bag when sealed causes them to naturally move to the optimal positions 28 relative to and in contact with the packaged unit 22.

Advantageously, when the cushion pieces 14, 114 are applied to the shipping bag 12, that enables the bag 12 and the cushioning to conform to the shape of the product being packaged. At the optimal locations 28, the cushion pieces 14, 114 provide the optimized load bearing for the particular product being shipped. Advantageously, the cushion pieces 14, 114 adhered to the shipping bag 12 allow for the exact amount of cushioning needed, and exactly where it is needed to protect any given product in transit. By utilizing the shipping bag 12 as the structure to encompass the product, the cushion pieces 14, 114 are then adhered to the bag in the exact locations required for optimized protection of the unit during drops and transit vibration.

Accordingly, the innovation of utilizing the exact amount of cushioning material needed to protect a product typically obviates the need to use an end cap or top and bottom tray assembly. The process of using the exact amount of cushioning material combined with locating and securing the cushioning material exactly where it is needed on the bag also allows for a single packaging process. As described herein, positioning the exact block form cushion pieces 14 in the exact place on the product 22 via the bag medium causes the cushion pieces to auto-locate to the exact positions on the product when the shipping bag 12 is placed on it.

As discussed herein, the design processes may vary from part to part depending on product dimensions, weight, and fragility. For instance, when there is a new product in need of this packaging solution, the thickness and bearing area of the cushion pieces 14 may be based on the product fragility, but also the product shape and dimensions. If there are fragile spots on the back of the product that can't withstand impact, the cushion pieces 14 would be placed on the areas that can support the impact. Then the shipping bag 12 would be designed and printed with indicators on the bag to show where to locate the cushion pieces 14.

As illustrated in FIGS. 15A and 15B, the hex-shaped cushion pieces 114 on the shipping bag 12 solves the same problem in an inherently different manner. The hex-shaped cushion pieces 114 adhered to the exact locations 28 on the shipping bag 12 as needed create their own cushioning needed by direction (6 sides to a box) by automatically finding their own locating point. Typically, the hex-shaped cushion pieces 114 are adhered to the outer surface 18 of the shipping bag 12. Instead of block shaped cushion pieces 14 to support any of the six (6) sides of the carton, the hex-shaped cushion pieces 114 automatically contour around the product 22 and then inside of the shipping carton 26. This effect can be best seen in FIG. 15B.

Optionally, as seen in FIGS. 14A and 14B, the packager may dispose end caps 24 on the ends of the bagged unit. In exemplary embodiments, extra cushion pieces 14, 114 could be used in this end cap design. For example, one or more cushion pieces 14, 114 could be disposed between an end cap 24 and the outer surface of the shipping 12 or within the space 30 defined in the end cap 24. Finally, the user places the bagged unit inside a shipping carton 26, seals the carton 26 using tape or other adhesives or fasteners, and ships the unit 22. It should be noted that the shipping system 10 could be re-used after the package is received, the bag 12 removed from the carton 26, the bag 12 opened, and the unit 22 removed from the bag 12. In testing of exemplary embodiments, the adhesive 20 remained on the surface of the shipping bag 12 and the cushion pieces 14 did not sustain damage, making the system suitable for re-use.

It should be noted that exemplary embodiments of packaging systems could be pre-fabricated and custom manufactured so packagers and shippers can use them without the need to perform most of the process described above. More particularly, customized shipping bags could be provided to manufacturers or distributors of commercially successful products pre-designed to ship those particular units. Those units would be evaluated as described above to determine their weight and dimensions and any particular distinctive features. Based on those specs and cushion material data, an appropriate shipping bag would be pre-selected and the proper number, size, and locations of the cushion pieces pre-selected and pre-adhered to the inner and/or outer surface of the bag. The packaging system comprising the shipping bag and the adhered cushion pieces could then be delivered to the product manufacturers or distribution centers to be used to ship those particular products. At those facilities, the user would only have to place the unit into the shipping bag, seal it, and the system would provide the optimized load bearing for that product. It should also be noted that disclosed packaging systems and methods could be used for storage of products before, after, or even without shipping the products.

By placing the exact amount of cushioning material needed on the product, the redundant costs to use added material to capture the product are avoided. Because disclosed embodiments advantageously use exactly the amount of packaging materials needed, they remove over 40% of the current material required to create a similar protective transit environment. Moreover, exemplary packaging systems are 100% recyclable and can be included in any recycle stream. The combination of the shipping bag and the cushioning pieces as described herein can be used for any product so almost any product manufacturer or distributor can take advantage of these benefits.

Packaging systems and methods described herein can be used for a wide variety of products and applications in a wide variety of industries. For example, they could be used for consumer electronics, for which the reduced costs, increased protection level, reusability, recyclability, and potential biodegradability would be advantageous. In medical packaging applications, the cleanliness, efficiency, and reusability would be particularly advantageous. For retail packaging, the reduced costs, would be advantageous. The devices' and systems' scalability, reduced costs, and reusability would be particularly advantageous for industrial uses. In the automotive industry, the reduced costs, reusability, and scalability would be advantageous. For shipping glass, the reduced costs, better protection level, and reusability would be particularly advantageous. For safety equipment, the systems' and methods' higher degree of impact protection, edge and corner protection, and personal impact protection would be advantageous.

Thus, it is seen that packaging systems and methods are provided. It should be understood that any of the foregoing configurations and specialized components or may be interchangeably used with any of the apparatus or systems of the preceding embodiments. Although illustrative embodiments are described hereinabove, it will be evident to one skilled in the art that various changes and modifications may be made therein without departing from the scope of the disclosure. It is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the disclosure. 

What is claimed is:
 1. A packaging system comprising: a shipping bag having an inner surface and an outer surface; and a plurality of cushion pieces directly affixed to the inner surface of the shipping bag by an adhesive.
 2. The system of claim 1 wherein the cushion pieces are dispersed at various locations within the shipping bag to protect a unit being packaged.
 3. The system of claim 2 wherein the cushion pieces are arranged to achieve optimal load bearing for a unit being packaged.
 4. The system of claim 3 wherein each cushion piece is located at an optimal location on the inner surface of the shipping bag relative to a unit being packaged.
 5. The system of claim 4 wherein each cushion piece automatically locates itself at an optimal location on the inner surface of the shipping bag relative to a unit being packaged.
 6. The system of claim 1 wherein the shipping bag is made of a waterproof material such that it provides a moisture barrier.
 7. The system of claim 1 further comprising a shipping carton configured to house the shipping bag.
 8. A method of packaging a unit for shipping, the method comprising: providing a shipping bag made of a material suitable for shipping, the shipping bag having an inner surface and an outer surface; providing a plurality of cushion pieces; determining an optimized load bearing for a unit to be shipped; determining an optimal location for each cushion piece relative to the unit based on the optimized load bearing; transferring each optimal location to one or more of the inner and outer surface of the shipping bag; and directly affixing each cushion piece to one or more of the inner and outer surface of the shipping bag at its optimal location using adhesive.
 9. The method of claim 8 wherein the step of determining an optimized load bearing for the unit to be shipped comprises weighing the unit and referring to cushioning curve data for the material of the shipping bag.
 10. The method of claim 8 further comprising placing the unit inside the shipping bag.
 11. The method of claim 10 further comprising sealing the shipping bag.
 12. The method of claim 11 wherein each cushion piece automatically locates itself at each respective optimal location on one or more of the inner and outer surface of the shipping bag relative to the unit.
 13. The method of claim 11 further comprising placing the shipping bag inside a shipping carton.
 14. The method of claim 13 further comprising removing the shipping bag from the shipping carton, unsealing the shipping bag, removing the unit from the shipping bag, and re-using the shipping bag to ship another unit.
 15. A packaging system comprising: a shipping bag having an inner surface and an outer surface; and a plurality of cushion pieces directly affixed to one or more of the inner and outer surface of the shipping bag by an adhesive, the cushion pieces being dispersed at various locations on one or more of the inner and outer surface of the shipping bag to protect a unit being packaged; wherein the cushion pieces are arranged to achieve optimal load bearing for the unit being packaged.
 16. The system of claim 15 wherein the optimized load bearing for the unit to be packaged is determined by a weight of the unit and cushioning curve data for the shipping bag.
 17. The system of claim 15 wherein each cushion piece is located at an optimal location on one or more of the inner and outer surface of the shipping bag relative to a unit being packaged.
 18. The system of claim 15 wherein each cushion piece automatically locates itself at an optimal location on one or more of the inner and outer surface of the shipping bag relative to a unit being packaged.
 19. The system of claim 15 wherein the shipping bag is made of polyethylene.
 20. The system of claim 15 wherein the cushion pieces are made of polyethylene. 